Floor sanding sponge pads

ABSTRACT

Floor sanding sponge pads (as referred to as “sponge pads”) are designed to sand both raw (unfinished) or treated (finished with stain, sealer, polyurethane, etc.) floors in order to smooth out surface roughness while applying a sufficient surface texture to allow subsequent application of finish to properly adhere. The sponge pad may have a vacuum hole configuration to remove swarf from the work surface.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/068,619, filed on Mar. 7, 2008. The entire teachings of the aboveapplication is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Floors are finished with a variety of materials to protect the surfacefrom physical or chemical damage. The process of finishing a floor oftenrequires the several sequential applications of coating material. Toadequately protect the floor surface, the coating contains chemicalsthat, once cured, repel or prevent other chemicals from directlycontacting and damaging the floor surface. However, this repellentproperty of the coating material can make intercoat adhesion in thesubsequent applications of the coating difficult. Mechanical abrasiontherefore is necessary to ensure proper adhesion of additional coatingapplications. Additionally, intercoat abrasion is utilized to removegrain raise, bubbles, and other debris that may have dried into thesurface of the coating. Abrasion is most commonly accomplished viasanding with fine grain paper.

Intercoat abrasion is a process for providing a consistent scratchpattern that will ensure adherence of subsequent coating layers, but notdiminish the overall appearance of the floor surface. Ideally, theintercoat abrasion step will produce fine scratches that will promotebonding between applied coats, but will not be visible following theapplication of subsequent coats.

Currently, intercoat abrasion is performed by using a nylon non-wovenpad in conjunction with a coated abrasive that is attached to thenon-woven pad via either a pressure sensitive adhesive or ahook-and-loop attachment. Alternatively, a sanding screen can be used.However, using two products in combination is problematic. The result ofa combination of two products may not be obvious based upon the functionof each product used separately, creating several issues for the user.First, the use of two products in conjunction requires the properinitial selection of each individual product. However, variables such asfloor type, finish, and equipment used prevents a straightforwardcombination of the two products. In addition, the number of coatedabrasive strips to be added to the pad may not be readily apparent tothe user. Another issue with the current products and methods is theinadvertent scratching from the swarf being trapped between theequipment and floor.

Therefore, there is a need for a product and method for abrading theintercoat layers during floor finishing, which can reduce or eliminateone or more of the above-mentioned problems.

SUMMARY OF THE INVENTION

The present invention generally relates to floor sanding sponges, and tomethods using such floor sanding sponge products.

A floor sanding sponge comprising at least one abrasive surfacesupported by a porous backing, wherein the abrasive surface definesopenings that provide, in conjunction with the porous backing, fluidcommunication from the abrasive surface through the porous backing to anopposite side of the sponge. In another embodiment, the abrasive surfaceand the porous backing define coterminous openings.

The porous backing includes either an open or closed cell foam material.In another embodiment, the foam material can be either a polyurethane ora polyethylene. In another embodiment, the porous backing includes alaminated scrim, which can be a flame laminated scrim.

An abrasive article backing surface can be used to fix the abrasivearticle to the porous backing. In one embodiment, an adhesive can beused to attach the abrasive surface to the porous backing. In anotherembodiment, a hook-and-loop fastener can be used to attach the abrasivesurface to the porous backing.

The sponge includes at least one adhesive surface. In anotherembodiment, the sponge includes two abrasive surfaces, each abrasivesurface being on an opposite side of the sponge. In another embodiment,at least one abrasive surface of the sponge defines a pattern. Theabrasive surface includes at least one abrasive component that isselected from the group consisting of 60 grit, 80 grit, 100 grit, 150grit and 180 grit.

In one embodiment, the sponge has a circular shape, and has a diameterin a range of between, for example, about 12 inches and about 20 inches.In yet another embodiment, the sponge has a diameter in a range ofbetween about 15 inches and 18 inches.

A method for sanding a floor includes abrading a surface with a floorsanding sponge having at least one abrasive. surface supported by aporous backing, wherein the abrasive surface defines openings thatprovide, in conjunction with the porous backing, fluid communicationfrom the abrasive surface through the porous backing to an opposite sideof the sponge.

In another embodiment, the surface being abraded has a floor treatment.In another embodiment, the floor treatment is a urethane. In oneembodiment of the method, the surface is abraded by manually directingthe floor sanding sponge across the surface. In another embodiment, thesurface is abraded by automated abrasion of the surface.

Many benefits result in the floor sanding sponge disclosed herein.First, the floor sanding sponge disclosed herein will perform the dutyof both the nylon non-woven pad/coated abrasive in one product. Second,the sponge material provides a compliancy or “give” to the sandingproduct that allows the grain to push up into the foam instead of intothe flooring, providing a softer and finer scratch pattern, resulting inbetter appearance of the floor surface. Another advantage, the spongepad can be rinsed out and reused, prolonging the life of the product. Inaddition, the vacuum hole configuration allows more efficient sandingdust removal, preventing inadvertent scratching and undesired shortingthe lifetime of the abrasive material.

BRIEF DESCRIPTION OF THE DRAWINGS

The FIGURE is a plan view of one embodiment of a floor sanding sponge ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

The floor sanding sponge pads (also referred to as “sponge pads”) of theinvention are designed to sand both raw (unfinished) or treated(finished with stain, sealer, polyurethane, etc.) floors in order tosmooth out the surface roughness, but still apply a sufficient surfacetexture to allow the subsequent application of finish to properlyadhere.

In one embodiment, the sponge pads use a foam sponge base that is coatedon both sides with abrasive grain. In another embodiment, the spongepads can be cut into specific shapes, mainly discs, but sometimessheets, and used in conjunction with floor sanding machines to performthe sanding application.

As used herein “porous backing” is derived from solid foam material.Foam materials can be classified as either “open cell” or “closed cell”based on pore structure. Open cell foams contain pores that areconnected to each other and form an interconnected network, with airfilling the spaces in the material. Closed cell foams do not haveinterconnected pores. Normally the closed cell foams have highercompressive strength due to their structures. In one embodiment the foamis bun stock and roll stock open cell polyurethane. In an alternativeembodiment, closed cell polyethylene is used for the foam material.

Abrasive particles or agglomerates of abrasive particles useful in theinvention can be of any conventional abrasive material utilized in theformation of abrasive products. Examples of suitable abrasive materialsfor use in the invention include diamond, corundum, emery, garnet,chert, quartz, sandstone, chalcedony, flint, quartzite, silica,feldspar, pumice and talc, boron carbide, cubic boron nitride, fusedalumina, ceramic aluminum oxide, heat treated aluminum oxide, aluminazirconia, glass, silicon carbide, iron oxides, tantalum carbide, ceriumoxide, tin oxide, titanium carbide, synthetic diamond, manganesedioxide, zirconium oxide, and silicon nitride.

The abrasive materials can be oriented or can be applied to thesubstrate without orientation (i.e., randomly), depending upon theparticular desired properties of the coated abrasive tools. In choosingappropriate abrasive particles or agglomerates of abrasive particles,characteristics, such as size, hardness, compatibility with workpiecesand heat conductivity, are generally considered. Abrasive particles oragglomerates of abrasive particles useful in the invention typicallyhave a particle size ranging from about 0.1 micrometer and about 1,500micrometers, such as from about 10 micrometers to about 1000micrometers.

“Abrasive article backing surface,” as that phrase is used herein,refers to a backing surface to which an abrasive article can be fixed.The abrasive article backing surface can be, for example, a plainsurface, a gripping surface, such as, e.g., a hook-and-loop system, oran adhesive surface. The abrasive article backing surface can be adaptedfor affixation to a particular style of abrasive article. Thus, in oneembodiment, an abrasive article includes a hook or loop fastenercomponent and the abrasive article backing surface includes a compatiblehook or loop fastener component. In another embodiment, roller coatingis used to adhere the abrasive material to the foam material with apaint roller.

In an alternative embodiment, antiloading composition (also known as ano fill) coating and proprietary grains can be added to the sponge pad.Examples of antiloading compositions are describe in more detail in theU.S. Pat. No. 7,195,658 and US. patent application Ser. Nos. 11/492,614,11/726,848 and 11/726,849, which are incorporated herein by reference.

In one embodiment, the abrasive article backing surface defines aplurality of openings in conjunction with the porous backing. The term“opening,” as used herein, refers to an opening such as hole, forexample, a circular, rectangular, triangular, or ring-shaped opening.For example, the openings can be arc-shaped.

The openings defined by the abrasive article backing surface can besymmetrically arranged about the abrasive article backing surface. Thebacking surface can include openings generally symmetric about one ormore axes of symmetry. For example, a disc-shaped abrasive articlebacking surface can include openings (e.g., circular, rectangular,triangular, ring-shaped, elongated, or arc-shaped openings) that can begenerally radially symmetric. A rectangular backing surface couldinclude openings generally symmetric about, for example, a longitudinalaxis of symmetry.

The abrasive surface defines openings that provide, in conjunction withthe porous backing, fluid communication from the abrasive surfacethrough the porous backing to an opposite side of the sponge.Preferably, the openings are configured such that swarf produced duringan abrasion process can be effectively transported through the abrasivearticle backing surface's openings to reach a support tool's dustextraction system.

The shape of the sponge may be modified to conform to the restraints ofthe drivers utilized by the particular floor sander. The sponge made canbe cut to conform to any size drive pad being used in the method. In oneembodiment, the sponge may be circular. In another embodiment, thediameter may range from 15 inches to 20 inches. In another embodiment,the diameter of the sponge is 16 inches.

The floor sanding sponges will work with pad drivers known in the art.Said pad drivers can be thin non-woven pads attached to the drive padassembly via small hooks. The floor sanding sponges can be attached tothe pad drivers and held in place by the weight of the machine.

Vacuum holes can be stamped into the sponge to aid in dust collection,although sponges can be used without vacuum holes. The holes provide aplace for excess sanding dust to collect. The floor sander is thenequipped with a dust shroud that encompasses drive pad to contain thedust and a dust port to allow attachment to a vacuum. In one embodiment,the vacuum holes allow the dust to be removed from the sanding surfacethrough the dust collection of the internal or external sanding machine.In another embodiment, the swarf removal can be facilitated by vacuumhole design and grain application.

In another embodiment, a laminated scrim is attached to one side of thesponge to give the foam material extra strength. In another embodiment,the laminated scrim material is flame laminated scrim.

A “floor treatment” refers to the coating of a floor surface with stain,sealant, or other such material that would protect the floor fromchemical and physical damage. In one such embodiment, a floor treatmentcan be a wax, urethane or polyurethane coating.

The method of this invention is designed to work in conjunction witheither rotary or orbital floor sanders. The floor sanding spongedisclosed in this method can be adapted for use on any machineregardless of motor type. Any machine specifically designed for floorsanding applications can be used with the floor sanding sponge of thisinvention. The sponge is designed to work in situations where anabrasive screen or non-woven pad would be abrading coats of finish onwood floors.

The FIGURE depicts one embodiment of a floor sponge pad of theinvention, where the floor sponge pad is cut into a disc 10 andarc-shaped openings 12 are radially stamped into the sponge material.

EXEMPLIFICATION

The following non-limiting examples represent various embodiments of afloor sanding sponge pad of the invention and methods to use the floorsanding sponge pads.

Example 1

A ¼″ foam from Rempac Foam Corporation (Clifton, N.J.) is covered withaluminum oxide (A/O) abrasive grain. The grain is applied to the ¼″ foamby using gravity to coat a resin system that locks the grain in place.The material is then cut into a 16″ disc with six dye-cut vacuum holes.The vacuum holes allow the finish dust that is sanded off the floor tobe collected by the vacuum system on the buffer.

Example 2

Materials

Sol-Gel (SG) coated, A/O coated between coat pads. Grits tested were 100grit for the SG, and 100, 120, 150 and 180 grit for the A/O. Testing wasconducted using a standard 16″ diameter rotary floor buffer, equippedwith dust collection. Products tested were compared against existing padand coat system of Norton 16′ Maroon Conditioning Pad part#6626100020566 and Norton Aluminum Oxide Pressure Sheet Rolls (PSA) in150, 180 and 220 grit.

Floor Sanding Method

The floor sanding sponge was used on a test floor of approximately 400square feet. The floor was sanded, stained, and finished with two coatsof Lenmar Rapid Seal Polyurethane, and two coats of BonaKemi Megawater-based urethane. The floor was divided into several sections totest each product by abrading after each coat of finish was applied. Theproducts were then evaluated after each section was abraded, and aftereach coat of finish was applied.

Product Evaluation

The products were evaluated on loading (comparison to the PSA);smoothness (ability to remove grain raise, bubbles, hairs, and debrisfrom the previous coat of finish); aggressiveness (ability to abrade thefinish without removing too much finish or cutting through the finishand sanding through the stain); and scratch pattern (quality of scratchpattern).

CONCLUSION

Both the SG and A/O products performed extremely well in all areas ofevaluation. All products had minimal loading and were comparable to thePSA Sheet Roll.

The SG pad in 100 grit and the A/O pads in 100 and 120 grit performedbest in abrading sealer coats of finish, which tended to require theremoval of more bubbles, debris, and raised wood fibers. The SG pad wasthe most aggressive; removing the most finish of all the productstested; yet still left a fine scratch pattern, and did not cut throughthe finish or stain. The A/O pads in 150 and 180 grit performed best onthe finish coats where there was minimal debris to remove, the leastamount of finish was removed, and the finest scratch pattern wasrequired. Multiple areas in the floor consisted of high spots andoverwood. While these areas would typically be prone to cutting throughthe finish or stain, neither the SG nor A/O products in any of the gritstested cut through the finish in these areas. All the products left avery fine scratch pattern, and no highlighted scratches or swirls werevisible following finish coat application. Even though the finish hadbeen abraded with multiple grits in different sections, the finishappeared uniform across its entirety.

Example 3

Materials

SG coated in 60 and 100 grit, A/O coated between coat pads in 100 and120 grit. Testing was conducted using a standard 16″ floor buffer.

Floor Sanding Method The floor sanding sponge was used on a test floorwith an existing polyurethane finish that was approximately 15 yearsold. Four separate areas of 100, 150, 150, and 200 square feet weretested. The two 150 square feet areas were rated as in poor condition,with paint spills, deep scratches, and heavily worn areas throughout.The 100 and 200 square foot areas were in fair condition and containedareas of normal wear and scratching. The floors were sanded, stained,and finished with two coated of BonaKemi Mega Semi-Gloss urethane. Theproducts were then evaluated after each section was abraded, and aftereach coat of finish was applied.

CONCLUSION

Thee 100 and 120 grit A/O pads were used in the 100 and 200 square feetareas, respectively, and both performed well. Both pads removed surfacescratches and left behind a fine scratch pattern, without wearing out.The 60 and 100 grit SG pads were used in the two 100 square feet areas.Both also left a fine scratch pattern while removing the paint stains,deep scratches, and worn spots, without wearing out. The finish wasuniform throughout the four areas, although each area had been abradedwith different grits in each room.

Equivalents

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

1. A floor sanding sponge comprising at least one abrasive surfacesupported by a porous backing, wherein the abrasive surface definesopenings that provide, in conjunction with the porous backing, fluidcommunication from the abrasive surface through the porous backing to anopposite side of the sponge.
 2. The floor sanding sponge of claim 1,wherein the abrasive surface and the porous backing define coterminousopenings.
 3. The floor sanding sponge of claim 1, wherein the porousbacking includes an open cell foam material.
 4. The floor sanding spongeof claim 3, wherein the foam material is a polyurethane.
 5. The floorsanding sponge of claim 1, wherein the porous backing includes a closedcell foam.
 6. The floor sanding sponge of claim 5, wherein the closedcell foam includes a polyethylene.
 7. The floor sanding sponge of claim1, further including an adhesive, wherein the abrasive surface isattached to the porous backing by the adhesive.
 8. The floor sandingsponge of claim 1, further including a hook-and-loop fastener, whereinthe abrasive surface is attached to the backing by the hook-and-loopfastener.
 9. The floor sanding sponge of claim 1, wherein the spongeincludes two abrasive surfaces, each abrasive surface being on anopposite side of the sponge.
 10. The floor sanding sponge of claim 1,wherein the porous backing includes a laminated scrim.
 11. The floorsanding sponge of claim 10, where the laminated scrim is a flamelaminated scrim.
 12. The floor sanding sponge of claim 1, wherein atleast one abrasive surface of the sponge defines a pattern.
 13. Thefloor sanding sponge of claim 1, wherein the abrasive surface includesat least one abrasive component that is selected from the groupconsisting of 60 grit, 80 grit, 100 grit, 150 grit and 180 grit.
 14. Thefloor sanding sponge of claim 1, wherein the sponge has a circularshape.
 15. The floor sanding sponge of claim 14, wherein the sponge hasa diameter in a range of between about 12 inches and 20 inches.
 16. Thefloor sanding sponge of claim 15, wherein the sponge has a diameter in arange of between about 15 inches and 18 inches.
 17. A method for sandinga floor comprising the step of abrading a surface with a floor sandingsponge comprising at least one abrasive surface supported by a porousbacking, wherein the abrasive surface defines openings that provide, inconjunction with the porous backing, fluid communication from theabrasive surface through the porous backing to an opposite side of thesponge.
 18. The method of claim 17, wherein the abrasive surface and theporous backing define coterminous openings.
 19. The method of claim 17,wherein the porous backing includes an open cell foam material.
 20. Themethod of claim 19, wherein the foam material is a polyurethane.
 21. Themethod of claim 17, wherein the porous backing includes a closed cellfoam.
 22. The method of claim 21, wherein the closed cell foam includesa polyurethane.
 23. The method of claim 17, further including anadhesive, wherein the abrasive surface is attached to the porous backingby the adhesive.
 24. The method of claim 17, further including ahook-and-loop fastener, wherein the abrasive surface is attached to thebacking by the hook-and-loop fastener.
 25. The method of claim 17,wherein the sponge includes two abrasive surfaces, each abrasive surfacebeing on an opposite side of the sponge.
 26. The method of claim 17,wherein the porous backing includes a laminated scrim.
 27. The method ofclaim 26, where the laminated scrim is a flame laminated scrim.
 28. Themethod of claim 17, wherein at least one abrasive surface of the spongedefines a pattern.
 29. The method of claim 17, wherein the abrasivesurface includes at least one abrasive component that is selected fromthe group consisting of 60 grit, 80 grit, 100 grit, 150 grit and 180grit.
 30. The method of claim 17, wherein the sponge has a circularshape.
 31. The method of claim 30, wherein the sponge has a diameter ina range of between about 12 inches and 20 inches.
 32. The method ofclaim 31, wherein the sponge has a diameter in a range of between about15 inches and 18 inches.
 33. The method of claim 17, wherein the surfacebeing abraded includes a floor treatment.
 34. The method of claim 33,wherein the floor treatment is a urethane.
 35. The method of claim 17,wherein the surface is abraded by manually directing the floor sandingsponge across the surface.
 36. The method of claim 17, wherein thesurface is abraded by automated abrasion of the surface.